High Productivity "DAVI Smart Line" technology is based on a guide system that automatically adjusts the position of the cone-shaped plate, guiding it to the plate roll while rotating slightly. It's a non-stop process that enables cone sections to be bent in less than ten minutes, before aligning the two edges to get a perfect cone section without the need for rerolling, or time-consuming plate set-ups.
The process begins with the cone data being entered on-screen, obtaining a complete automatic process list. The plate is then placed on the infeed conveyor, where special pushers and guides move it automatically to the centreline until the end of the process.
High Productivity "DAVI Smart Line" features a new DAVI 4 roll, designed in 2015 with intraframes and sturdy steel beams. A hydraulic guiding system enables the infeed conveyor and tilt-table to hold heavy plates of different lengths up in the air safely while pre-bending, and to guide the cone-shaped plates automatically in an extremely efficient and continuous cone-forming process.
High Productivity "DAVI Smart Line", which supersedes the previous semi-automatic system, not only centres the plate on the infeed conveyor, but also keeps it aligned along the full rolling process. A combination of mechanics, hydraulics and electronics enables an entirely automatic cycle, from plate placing to can removal.
The entire cycle is managed by the DAVI iRoll PRO with the new iCone technology, which was specially designed by DAVI's software developers. It is able to build the full sequence, so that the operator would have only to load the plate on the conveyor, push the 'start' button and for wait the end of the process - typically after eight to ten minutes - when the cone would be ready for tack welding.
High Productivity "DAVI Smart Line" was introduced to the most important players in the wind tower fabrication industry at the wind energy seminars that took place at DAVI's headquarters in Cesena, Italy, in October 2017, together with technical partners PEMA, HGG and Lincoln. A live demonstration showed how the rolling process could be reduced to less than ten minutes with a single operator in a CNC-assisted process for inshore towers; it is also theoretically possible to form a cone in automatic mode.
The rolling line was realised by combining the experience and skills of DAVI's technical, and research and development departments. The system can work in a totally automatic way to boost productivity while improving the quality of the finished product. The handling systems make it possible to position the sheet automatically on the loading table and to make it advance precisely during processing without intermediate stops and the need to check the diameters.
High Productivity "DAVI Smart Line" is used also for offshore towers. The requirements here are slightly different; due to the size and the weight of the plates, it is preferable to use a progressive step sequence with repeated repositioning of plates by the guiding system.
High Productivity "DAVI Smart Line" evolved from DAVI's well-known high-productivity package, which was conceived in cooperation with the most important wind tower manufacturers to eliminate bottlenecks in the rolling cycle, reduce labour and improve the bending process, thanks to an innovative, patented tilting conveyor.
It is now possible to have an automatic cycle that improves the quality of the rolled cans, within the tightest tolerances demanded by the market.
The responses so far has been highly positive. After it was introduced to the industry at the Wind Energy 2017 Seminar, several rolling lines have already been installed at some of the most important companies in the wind energy sector, which are now enjoying the advantages offered by DAVI's new system.